Sub-10 nm line features via rapid graphoepitaxial self-assembly of amphiphilic monolayers

ABSTRACT

Methods for fabricating sublithographic, nanoscale microchannels utilizing an aqueous emulsion of an amphiphilic agent and a water-soluble, hydrogel-forming polymer, and films and devices formed from these methods are provided.

TECHNICAL FIELD

Embodiments of the invention relate to nanofabrication techniques and, more particularly to methods for preparing nanoscale microstructures and microchannels, and devices resulting from those methods.

BACKGROUND OF THE INVENTION

As the development of nanoscale mechanical, electrical, chemical and biological devices and systems increases, new processes and materials are needed to fabricate such devices and components. Optical lithographic processing methods are not able to accommodate fabrication of structures and features at the nanometer level. The use of self assembling diblock copolymers presents another route to patterning at nanometer dimensions. Diblock copolymer films spontaneously assembly into periodic structures by microphase separation of the constituent polymer blocks after annealing, for example by thermal annealing above the glass transition temperature of the polymer or by solvent annealing, forming ordered domains at nanometer-scale dimensions. Following self assembly, one block of the copolymer can be selectively removed and the remaining patterned film used as an etch mask for patterning nanosized features into the underlying substrate. Since the domain sizes and periods (L_(o)) involved in this method are determined by the chain length of a block copolymer (MW), resolution can exceed other techniques such as conventional photolithography, while the cost of the technique is far less than electron beam (E-beam) lithography or EUV photolithography which have comparable resolution.

The film morphology, including the size and shape of the microphase-separated domains, can be controlled by the molecular weight and volume fraction of the AB blocks of a diblock copolymer to produce lamellar, cylindrical, or spherical morphologies, among others. For example, for volume fractions at ratios greater than about 80:20 of the two blocks (AB) of a diblock polymer, a block copolymer film will microphase separate and self-assemble into a periodic spherical domains with spheres of polymer B surrounded by a matrix of polymer A. For ratios of the two blocks between about 60:40 and 80:20, the diblock copolymer assembles into a periodic hexagonal close-packed or honeycomb array of cylinders of polymer B within a matrix of polymer A. For ratios between about 50:50 and 60:40, lamellar domains or alternating stripes of the blocks are formed. Recently, graphoepitaxy, which involves the use of lithographical-defined topographical features to direct block copolymer assembly, has been used in forming registered, self-assembled diblock copolymer structures.

Although diblock copolymers are receiving attention for the ability to self-assemble and form sub-lithographic ordered features, there are inherent limitations in the use of these materials including an approximate minimal feature size of 10 nm and relatively slow rates of formation of ordered structures on the order of hours.

It would be useful to provide a method of fabricating nanoscale microstructures and microchannels that overcome these problems.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are described below with reference to the following accompanying drawings, which are for illustrative purposes only. Throughout the following views, the reference numerals will be used in the drawings, and the same reference numerals will be used throughout the several views and in the description to indicate same or like parts.

FIG. 1 illustrates a diagrammatic top plan view of a portion of a substrate at a preliminary processing stage according to some embodiments of the present disclosure, showing the substrate with trenches. FIG. 1A is an elevational, cross-sectional view of the substrate depicted in FIG. 1 taken along lines 1A-1A.

FIGS. 2-5 illustrate diagrammatic top plan views of a portion of a substrate at various stages of processing according to an embodiment of the present disclosure to provide hydrophilic trench ends. FIGS. 2A-5A and 2B-5B illustrate elevational, cross-sectional views of the substrate shown in FIGS. 2-5 taken along lines 2A-2A to 5A-5A and lines 2B-2B to 5B-5B, respectively.

FIG. 6 illustrates an elevational, cross-sectional view of a portion of the substrate depicted in FIGS. 1-1A at a subsequent processing step according to another embodiment of the disclosure to provide hydrophilic trench ends.

FIGS. 7-8 illustrate diagrammatic top plan views of the substrate shown in FIG. 6 in subsequent processing steps. FIGS. 7A-8A are elevational, cross-sectional views of the substrate shown in FIGS. 7-8 taken along lines 7A-7A and 8A-8A, respectively.

FIG. 9 is an elevational, cross-sectional view of the substrates shown in FIGS. 9A and 9B. FIGS. 9A-9B (taken along lines 9A/9B-9A/9B of FIG. 9) are diagrammatic top plan views of the substrates shown, respectively, in FIG. 5 and FIG. 1 at a subsequent processing step, according to different embodiments of the disclosure.

FIG. 10 illustrates an elevational, cross-sectional view of the substrate shown in FIG. 9A at a subsequent processing step.

FIGS. 11-12 are diagrammatic top plan views of the substrate of FIG. 10 at subsequent processing stages. FIGS. 11A-12A are elevational, cross-sectional views of the substrate shown in FIGS. 11-12 taken along lines 11A-11A and 12A-12A, respectively.

FIG. 13 illustrates a diagrammatic top plan view of a portion of a substrate at a preliminary processing stage according to another embodiment of the present disclosure. FIGS. 13A-13B are elevational, cross-sectional views of the substrate depicted in FIG. 13 taken along lines 13A-13A and 13B-13B, respectively.

FIG. 14 is a diagrammatic top plan view of the substrate shown in FIG. 13 at a subsequent processing stage. FIGS. 14A-14B are elevational, cross-sectional views of the substrate shown in FIG. 14, taken along lines 14A-14A and 14B-14B, respectively. FIG. 14C is an elevational, cross-sectional view of the another embodiment of the substrate shown in FIG. 14, taken along lines 14C-14C.

FIG. 15 illustrates an elevational, cross-sectional view of the substrate shown FIG. 14A, at a subsequent processing step.

FIGS. 16-17 illustrate a diagrammatic top plan view of the substrate shown in FIG. 15 at a subsequent processing stage. FIGS. 16A-17A and 16B-17B are elevational, cross-sectional views of the substrate shown in FIGS. 16-17 taken, respectively, along lines 16A-16A, lines 17A-17A, lines 16B-16B, and lines 17B-17B.

FIGS. 18A-18B are elevational, cross-sectional views of the substrate shown in FIG. 17 taken, respectively, along lines 18A-18A and lines 18B-18B, at a subsequent processing stage.

FIG. 19 is an elevational, cross-sectional view of the substrate shown in FIG. 18A at a subsequent processing stage.

FIGS. 20-24 are elevational, cross-sectional views of the substrate shown in FIG. 5B at subsequent processing stages according to another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The following description with reference to the drawings provides illustrative examples of devices and methods according to embodiments of the invention. Such description is for illustrative purposes only and not for purposes of limiting the same.

In the context of the current application, the term “semiconductor substrate” or “semiconductive substrate” or “semiconductive wafer fragment” or “wafer fragment” or “wafer” will be understood to mean any construction comprising semiconductor material, including but not limited to bulk semiconductive materials such as a semiconductor wafer (either alone or in assemblies comprising other materials thereon), and semiconductive material layers (either alone or in assemblies comprising other materials). The term “substrate” refers to any supporting structure including, but not limited to, the semiconductive substrates, wafer fragments or wafers described above.

“L_(o)” is the inherent pitch (bulk period or repeat unit) of structures that self assemble upon annealing from a self-assembling (SA) block copolymer or a blend of a block copolymer with one or more of its constituent homopolymers.

“Hydrogels” are cross-linked soluble polymers that swell because of an affinity for water but do not dissolve in water due to structural and/or chemical crosslinks.

The methods overcome limitations of fabricating films from self-assembling block copolymers. In embodiments of the invention, the methods utilize a trench template defined either lithographically or by use of a film template formed by the graphoepitaxial self-assembly of a lamellar block copolymer inside a wider trench and selective removal of one of the assembled blocks to form films that can be utilized, for example, in etching sub-10 nm features in a substrate.

Steps in a method for fabricating nanoscale microstructures and microchannels according to an embodiment of the invention are illustrated in FIGS. 1-12.

Referring to FIGS. 1-1A, a substrate 10 with an overlying material layer 12 is shown. In the described embodiment, the material layer 12 is patterned to form trenches 14. The trenches can be formed using a lithographic technique such as photolithography, extreme ultraviolet (EUV) lithography, proximity X-rays, electron beam (e-beam) lithography, as known and used in the art. Conventional photolithography can provide trenches with widths down to about 60 nm. E-beam and EUV lithography can produce smaller features, although at a slower rate and higher expense.

A method called “pitch doubling” or “pitch multiplication” can also be used for extending the capabilities of photolithographic techniques beyond their minimum pitch, as described, for example, in U.S. Pat. No. 5,328,810 (Lowrey et al.), US 2006/0281266 (Wells) and US 2007/0023805 (Wells), the disclosures of which are incorporated by reference herein. Briefly, a pattern of lines is photolithographically formed in a photoresist layer overlying a layer of an expendable material, which in turn overlies a substrate, the expendable material layer is etched to form placeholders or mandrels, the photoresist is stripped, spacers are formed on the sides of the mandrels, and the mandrels are then removed leaving behind the spacers as a mask for patterning the substrate. Thus, where the initial photolithography formed a pattern defining one feature and one space, the same width now defines two features and two spaces, with the spaces defined by the spacers. As a result, the smallest feature size possible with a photolithographic technique is effectively decreased down to about 30 nm or more.

In some embodiments, trenches or grooves with widths in the about 10-30 nm range can be defined using techniques involving graphoepitaxial self-assembly of lamellar-phase block copolymers to provide an etch mask for patterning underlying substrate stacks, e.g. silicon over silicon oxide, as described with reference to FIGS. 13-19.

As illustrated in FIGS. 1-1A, each trench 14 is structured with opposing sidewalls 16, opposing ends (edges) 18, a floor or bottom surface 20, a width (w_(t)), a length (l_(t)) and a depth (D_(t)). In some embodiments, the trench dimension is about 20-200 nm wide (w_(t)) and about 1600-2400 nm in length (l_(t)), with a depth (D_(t)) of about 50-500 nm. Substrate 10 is exposed as the floor 20 of the trench and a portion of the material layer 12 forms a spacer interval or crest 12 a between the trenches. The trenches 14 are structured such that the sidewalls 16 are hydrophobic and preferential wetting to the surfactant component of the described polymer/surfactant emulsion, and the trench floor 20 is hydrophilic such that the polymer component will assemble within the center of the trench.

In some embodiments, the substrate 10 is composed of an oxide layer (e.g., silicon oxide, SiO_(x)) and the material layer 12 is a silicon layer (with native oxide). Hydrophobic trench sidewalls 16 and ends 18 can be provided by removing the native oxide from the surface of a silicon layer 12 within the trenches to form hydrogen-terminated silicon. H-terminated silicon can be prepared by a conventional process, for example, by a fluoride ion etch of silicon (with native oxide present), for example, by immersion in an aqueous solution of hydrogen fluoride (HF) or buffered HF and/or ammonium fluoride (NH₄F), by HF vapor treatment, by exposure to hot H₂ vapor or by a hydrogen plasma treatment (e.g., atomic hydrogen).

In other embodiments, including embodiments in which the surfactant material layer (24) is removed by a wet extraction process (FIGS. 12-12A), the material layer 12 can be composed of a carbonaceous film such as amorphous carbon, which is semi-graphitic but not crystalline in nature, to provide hydrophobic trench sidewalls 16 and ends 18. In some embodiments, the amorphous carbon can be a form of transparent carbon that is highly transparent to light. Deposition techniques for forming a highly transparent carbon can be found in A. Helmbold, D. Meissner, Thin Solid Films, 1996, 283:196-203, the disclosure of which is incorporated herein by reference. In addition, amorphous carbon layers can be formed by chemical vapor deposition using a hydrocarbon compound, or mixtures of such compounds, as carbon precursors such as ethylene, propylene, toluene, propyne, propane, butane, butylene, butadiene and acetylene. A suitable method for forming amorphous carbon layers is described in U.S. Pat. No. 6,573,030 (Fairbairn et al.), the entire disclosure of which is incorporated herein by reference.

The trench floors 20 (e.g., of silicon oxide, which is inherently hydrophilic) can then be treated to provide a selectively graftable surface. In some embodiments, a ligand (anchor, linker) having a reactive moiety (e.g., an end group) can be grafted onto the surface of the oxide layer 10 (with the reactive moiety oriented toward the center of the trench). For example, in embodiments using a Click-based chemistry reaction for the formation of a hydrogel composed of PEO or PEG, an example of a useful linker or ligand is poly(ethylene glycol) (PEG) functionalized with an alkyne group, as described, for example, in Malkoch et al., Chem. Commun. 2006, 2774-2776, the disclosure of which is incorporated herein by reference. As described in Malkoch, PEG can be reacted with excess anhydride (e.g., 4-pentynoic anhydride) to derivatize both ends of the PEG moiety with alkyne groups. To provide a derivatized PEG ligand having a reactive end group that can be grafted onto the surface of an oxide layer, PEG can be reacted with an anhydride in an about 1:1 ratio to derivatize one end of the PEG moiety with an alkyne group and the other end with a hydroxyl group. The mono-hydroxylated PEG ligands can then be grafted to an oxide (e.g., SiO₂) surface by spin-coating (e.g., from a 1% w/v solution in toluene) and heating to allow the terminal OH groups to diffuse to and react with the oxide layer, as described, for example, in Mansky et al., Science, 1997, 275 (5305), 1458-1460, the disclosure of which is incorporated by reference herein. The PEG group of the attached ligand provides a linker to the PEG or PEO moieties from the hydrogel emulsion. Non-grafted material can be removed by rinsing with an appropriate solvent (e.g., toluene).

In another embodiment, an alkyne-functionalized PEG ligand containing a silane group such as trichlorosilane or trialkoxysilane can be grafted to an oxide surface. For example, a mono-hydroxylated PEG ligand can be reacted with tetrachlorosilane (SiCl₄) or tetraethoxysilane Si(OC₂H₅)₄ to produce the desired compound, which can be applied to the trench floors 20, for example, by spin-on application. Conditions for the application of trialkoxy and trichlorosilane compounds is described, for example, by Barry Arkies, Silane Coupling Agents. Connecting Across Boundaries (v2.0), Gelest, Inc., Morrisville, Pa. (2006), the disclosure of which is incorporated herein.

In other embodiments using a free radical polymerization process for the preparation of the hydrogel, an example of a suitable linker is PEG polymer functionalized with an acrylate group at one end such as a PEG acrylate, or PEG methacrylate, which can be obtained from a commercial source such as Sigma-Aldrich Co. (St. Louis, Mo.).

In other embodiments, the surface of both the trench floor 20 and the trench ends 18 can be treated to be hydrophilic such that aqueous phase of the emulsion wets both the trench floor 20 and ends 18, and the surfactant layer forms solely along the hydrophobic trench sidewalls 16, as in FIGS. 9-9A. In some embodiments, the material layer 12 can be structured to provide a silicon surface exposed at the sidewalls 16 which is treated to remove native oxide to form H-terminated silicon, and an oxide surface exposed at the ends (edges) 18 (and floor 20) of the trenches which is treated with a PEG ligand.

For example, referring to FIGS. 2-2B, a layer 12 of silicon can be deposited and etched lithographically to form trenches 11 that expose an underlying SiO_(x) layer 10. Then, as illustrated in FIG. 3-3B, a layer 13 of SiO_(x) can be deposited to overfill the trenches 11 and removed, for example by chemical-mechanical planarization (CMP), to expose the surface of the silicon layer 12 and SiO_(x) 13 within the trenches 11, as shown in FIGS. 4-4B. As depicted in FIGS. 5-5B, the silicon layer 14 can then be etched lithographically using a photoresist mask to define the trenches 14 with the SiO_(x) layer 10 exposed as the trench floor 20, the SiO_(x) layer 13 as the trench ends 18, and the silicon layer 12 exposed as the sidewalls 16.

In another embodiment, a layer 12′ of silicon can be deposited and etched lithographically to form trenches 14′ that expose an underlying SiO_(x) layer 10′ (as in FIGS. 1-1A). Then, as illustrated in FIG. 6, a layer 13′ of SiO_(x) can be deposited to overfill the trenches 14′ and removed, for example by chemical-mechanical planarization (CMP), to expose the surface of the silicon layer 12′ and SiO_(x) 13′ within the trenches 14′, as shown in FIGS. 7-7A. As depicted in FIGS. 8-8A, portions of the SiO_(x) layer 13′ can then be etched lithographically using a photoresist mask to redefine the trenches 14′ with the SiO_(x) layer 10′ exposed as the trench floor 20′, the SiO_(x) layer 13′ as the trench ends 18′, and the silicon layer 12′ exposed as the sidewalls 16′.

In either of the embodiments depicted in FIGS. 5-5B or FIGS. 8-8A, an aqueous fluoride treatment can be briefly conducted to remove native oxide on the silicon layer 12 (to form H-terminated silicon sidewalls) while minimizing etching of the SiO_(x) layers 10, 13. A PEG coupling agent can then be applied and bound to hydroxyl (—OH) groups on the SiO_(x) floor 20 and ends 18 of the trenches 14 in an inert atmosphere (e.g., nitrogen, argon, etc.) to minimize the reformation of native oxide on the silicon sidewalls 16.

Referring now to FIG. 9, an aqueous emulsion layer 22 composed of an amphiphilic agent (e.g., surfactant) and a water-soluble, hydrogel-forming polymer, with optional additives, is applied to fill the trenches 14 and over the material layer 12 (and layer 13). The polymer/surfactant emulsion can be applied, for example, by casting, dip coating, spray coating, knife-edge coating, spin casting (spin-coating), and the like, such that the emulsion layer 22 is maintained in a liquid consistency to allow the hydrogel to set up and the surfactant monolayer to form at the trench sidewalls 16. Application of the emulsion can be conducted at about room temperature (e.g., about 20-25° C.) to up to about 95° C.

Upon application of the emulsion, the surfactant component will self-assemble to form a monolayer (SAM) 24 along the hydrophobic trench surfaces, with a thickness of about 10 nm or less, typically about 3-10 nm, or about 3 nm. The establishment of the surfactant monolayer at the hydrophobic trench sidewalls 16 is dependent, at least in part, on the presence of water. The aqueous phase 26 of the emulsion comprising the polymer component orients to the hydrophilic floors 20 at the center of the trenches. The rate of self-assembly of the surfactant monolayer (SAM) is relatively rapid at about 0.1-1 minute (or less), and is generally limited by the rate of diffusion of the surfactant to the hydrophobic surfaces (e.g., sidewalls).

As illustrated in FIG. 9A, in embodiments in which the sidewalls 16 are hydrophobic (e.g., H-terminated silicon) and the trench floor 20 and ends 18 are hydrophilic, the formation of the surfactant layer 24 will occur solely along the trench sidewalls 16 with the polymer phase 26 of the emulsion wetting the trench floor 20 and ends 18. In other embodiments in which both the trench sidewalls 16 and ends 18 are hydrophobic, the surfactant component of the emulsion will form a layer 24 on both the trench ends and sidewalls, as shown in FIG. 9B.

Suitable water-soluble and hydrogel-forming polymers include, for example, poly(ethylene oxide) (PEO) and poly(ethylene glycol) (PEG). An example of a PEG-based hydrogel material is described in Malkoch et al., “Synthesis of well-defined hydrogel networks using Click chemistry,” Chem. Commun., 2006, 2774-2776, the disclosure of which is incorporated by reference herein. Briefly, a PEG-based hydrogel material can be prepared using Click chemistry, a copper-catalyzed cycloaddition azide/acetylene coupling reactions, by reacting diacetylene-functionalized and tetraazide-functionalized PEG derivatives at room temperature under aqueous conditions in the presence of copper sulfate (CuSO₄) and sodium ascorbate as a reducing agent; the hydrogel can form in less than about 30 minutes at about room temperature.

In other embodiments, the hydrogel can be synthesized by the photopolymerization of water-soluble vinyl monomers using visible or UV irradiation to form water-soluble polymers with two or more reactive groups, as described, for example, by Nguyen K T, West J L, “Photopolymerizable Hydrogels for Tissue Engineering Applications,” Biomaterials, 2002; 23:4307-14, the disclosure of which is incorporated by reference herein. Examples of photopolymerizable macromers include: PEG acrylate derivatives (e.g., Sawhney, et al., “Bioerodible hydrogels based on photopolymerized poly(ethylene glycol)-co-poly(α-hydroxy acid) diacrylate macromers,” Macromolecules, 1993, 26(4), 581-587); PEG methacrylate derivatives (e.g., Elisseeff et al., “Photoencapsulation of chondrocytes in poly(ethylene oxide)-based semi-interpenetrating networks,” J. Biomedical Materials Res., 2000, 51(2), 164-171; Kim et al., “Self-assembled hydrogel nanoparticles composed of dextran and poly(ethylene glycol) macromer,” Int. J Pharm., 2000, 205(1-2), 109-116; polyvinyl alcohol (PVA) derivatives (e.g., U.S. Pat. No. 5,849,810 (Muller, Photocrosslinked polymers); Martens and Anseth, “Characterization of hydrogels formed from acrylate modified poly(vinyl alcohol) macromers,” Polymer, 2000, 41(21), 7715-7722); and modified polysaccharides such as hyaluronic acid derivatives (e.g., Matsuda et al., ASAIO j., 1992, 38(3), M154-M157; Bulpitt et al., J. Biomed. Mater. Res., 1999, 47(2), 152-169 (hyaluronic acid-based hydrogels)), and dextran methacrylate (e.g., Kim et al., J. Biomed. Mater. Res., 2000, 49(4), 517-527, and Kim et al., J. Biomaterials Application, 2000, 15(1), 23-46 (dextran-methacrylate hydrogel), the disclosures of which are incorporated by reference herein.

In other embodiments, the hydrogel can be synthesized by the free radical-induced cross-linking of PEG-diacrylates or PVA-diacrylates, as described, for example, by Martens and Anseth, Polymer, 2000, 41(21), 7715-7722 (acrylate-modified poly(vinyl alcohol) hydrogels); Lin-Gibson et al., Macromolecules, 2005, 38(7), 2897-2902 (photopolymerizable PEG dimethacrylate hydrogels); Guo et al., J. Polym. Sci. Polym. Chem., 2005, 43, 3932-3944 (biodegradable unsaturated poly(ester-amide)s/PEG diacrylate hydrogels); and Gudipati et al., J. Polymer Science Part A. Polymer Chemistry, 2004, 42(24), 6193-6208 (hyperbranched fluoropolymer and linear PEG-based amphiphilic crosslinked networks), the disclosures of which are incorporated by reference herein.

In yet other embodiments, the hydrogel can be synthesized by crosslinking cysteine-based peptides with vinyl sulfone-functionalized multiarmed PEG macromers, as described, for example, by Lutolf et al., Adv. Mater., 2003, 15(11), 888-892 (cell-responsive synthetic hydrogels), the disclosure of which is incorporated by reference herein. In other embodiments, the hydrogel can be synthesized from PEG macromers and dendritic peptide crosslinkers, as described, for example, by Wathier et al., J. Am. Chem. Soc., 2004, 126 (40), 12744-12745 (peptide dendron with terminal cysteine residues mixed with PEG dialdehyde), the disclosure of which is incorporated by reference herein.

The polymer is combined with an amphiphilic surfactant (exhibits both hydrophilic and lipophilic (hydrophobic) characteristics) that will form a self-assembled monolayer (SAM) on the hydrophobic surfaces of the trench. Suitable amphiphilic surfactants include, for example, phospholipids (anionic surfactants) such as phosphatidylcholines (PC), phosphatidylserines (PS), phosphatidylethanolamines, phosphatidylinositols, phosphatidylglycerols, phosphatidic acids, lysophospholipids, among others. Examples of suitable phosphatidylcholines (PC) include dipalmitoyl-PC (DPPC), 1-palmitoyl-2-oleoyl-PC (POPC), dioleoyl-PC (DOPC), and dilinoleoyl-PC (DLiPC), among others. Other useful surfactants include nonionic surfactants such as octylphenol ethoxylates, for example, TRITON™-X Series surfactants such as Triton™-X 100 (C₁₄H₂₂O (C₂H₄O)_(n) where n=9-10)), among others.

The surfactant is included in the emulsion at a concentration effective to form a monolayer 24 having a thickness of about 10 nm or less or about 3-10 nm. A suitable emulsion can be formulated with an about 5-15 w/w % of the polymer and an about 0.5-5 w/w % of the surfactant, based on the total weight of the emulsion.

Optionally, the emulsion can include a crosslinking adjuvant or catalyst/cocatalyst. For example, in the use of Click chemistry to synthesize a PEG-based hydrogel material, the emulsion can include copper sulfate (e.g., at about 1% w/w) and sodium ascorbate, whereby the emulsion would be directly or about immediately dispensed. In the use of free radical cross-linking chemistry to synthesize the hydrogel material, an appropriate peroxide or photoinitiator can be included, and the emulsion layer can be cross-linked by exposure to UV light, focused e-beam, heat, etc., as appropriate to crosslink the polymer to form a hydrogel.

As a further option, the emulsion can include a compatible organic solvent to modify the thickness of the surfactant layer over a range of about 3 nm to up to about 10 nm. Suitable solvents include, for example, C₈-C₂₄ alkanes (e.g., octane, nonane, decane, undecane, dodecane, etc.), cycloalkanes (e.g., cyclopentane, cyclohexane, etc.), and aromatic hydrocarbons (e.g., benzene, toluene, etc.).

In addition, the emulsion can optionally include one or more hardening agents to fill or strengthen the hydrogel. Suitable hardening agents include, for example, inorganic nanoparticles such as silicon dioxide (SiO₂), metal oxides such as zirconium oxide (ZrO₂), titanium dioxide (TiO₂), cerium dioxide (CeO₂), aluminum oxide, Al₂O₃), iron oxide, vanadia and tin oxide, carbonates such as calcium carbonate, and carbon black. Solvated metals that can be precipitated can also be used as hardening agents. For example, in the use of Click chemistry to synthesize the hydrogel, the inclusion of a copper catalyst at about 1% w/w that precipitates after formation of the hydrogel can provide strengthening of the gel. Other examples of solvated metals that can be used as hardening agents are described, for example, in Mindel, et al., J. Am. Chem. Soc., 1943, 65, 2112 (using electrochemical reduction of metals under water to produce sols of Pb, Sn, Au, Pt, Bi, Sb, As, Tl, Ag, and Hg), the disclosure of which is incorporated by reference herein.

An embodiment of a suitable emulsion composition can be formulated with:

-   -   about 5-15 w/w % water-soluble, hydrogel-forming polymer;     -   about 1-5 w/w % amphiphilic surfactant;     -   about 0-5 w/w % organic solvent;     -   about 0-20 (or more) w/w % hardening agent;     -   about 0-5 w/w % cross-linking adjuvants; and     -   about 94-55 w/w % water.

In some embodiments, after formation of the hydrogel 26 within the trenches, a liquid filler material can be applied to the surfactant monolayer 24 and hydrogel 26 to reduce the impact of drying on the shape and adherence of the surfactant monolayer to the hydrophobic trench surfaces and to further strengthen and reduce the porosity of the polymer hydrogel such that the shape of the hydrogel shape is retained after removal of the surfactant monolayer and it functions as an adequate mask during a plasma etching process (FIG. 12A, element 28).

For example, in addition to the incorporation of inorganic nanoparticles as hardening agents, a silicon ester such as tetraethoxysilane or tetraethyl orthosilicate (TEOS, Si(OC₂H₅)₄) (either neat or as solution in organic solvent or water) can be applied and allowed to diffuse into the hydrogel 26 to form a silicon oxide gel via conventional sol-gel reaction to fill in the shape of the hydrogel with an inelastic material. The diffusion process can be expedited by formulating an aqueous solution having either an acidic or basic pH. In embodiments in which the hydrogel includes an oxide hardening agent (e.g., SiO₂, TiO₂, etc.), the resulting sol (e.g., silica sol) acts to fuse or precipitate the separate particles of the hardening agent into a contiguous mass or suspension within the hydrogel to further harden the hydrogel, which can remain partially porous.

In other embodiments, the surfactant monolayer 24 can be formed as described in U.S. Pat. No. 6,884,842 (Soane), the entire disclosure of which is incorporated by reference herein. Briefly, surfactant monomers containing olefinic group(s) with surface functional head groups that are complementary to a substrate surface, are applied to and self-assemble at a micelle-like interface on the substrate. The positions of the functional groups on the substrate are then stabilized by crosslinking reactive groups on the monomers by a free radical polymerization method to form a thin, insoluble polymer network or mat. The resulting surfactant monolayer 24 has high thermal and solvent stability, is robust against the removal of water, and is not disrupted by organic solvents such as alcohols that are released during formation of a sol. The monomers for forming the surfactant monolayer 24 are structured with a head group (e.g., alcohols, carboxylic acids, amides, amines, phosphates, sugars, disaccharides, etc.), a crosslinking group (e.g., a free radically polymerizable moiety such as acrylates, methacrylates, acrylamides, vinyl ethers, epoxides, etc.), and a tail group fabricated and designed to have surfactant functionality. Examples of compounds include acryloylated sulfosuccinic acid ester surfactants such as (bis(11-acryloylundecyl)sulfosuccinate), (bis-(3-acryloyl-2-ethylhexyl)sulfosuccinate) and (bis-2-acryloyldodecyl sulfosuccinate), and hydroxybenzoic acids such as glycine-headed-tris(11-acryloyloxyundecyloxy)benzamide and ethanolamine-headed-tris(11-acryloyloxyundecyloxy) benzamide, which can be prepared as described in U.S. Pat. No. 6,884,842.

Self-assembly of the monomers to form the surfactant monolayer 24 proceeds by surface aggregation of the head groups at the water interface with the tail groups organized on hydrophobic surfaces 12. Polymerization and crosslinking of the monomers can be accomplished by known reaction methods, including free-radical polymerization, which can include the application of or radiation, such as UV light to accelerate the process. Functional groups such as acrylates can be polymerized by heat or radiation such as UV light. In some embodiments, the polymerization of the crosslinking groups along the backbone after self assembly is conducted. Other crosslinking reactions known in the art such as ring opening, condensation, group transfer, anionic and cationic polymerization can optionally be used. Catalysts and/or photo- or thermal initiators can optionally be used to promote crosslinking. Examples of crosslinking groups include acrylates, methacrylates, acrylamides, vinyl ethers, and epoxides, methacrylamide, vinylbenzene, α-methylvinylbenzene, divinylbenzene, epoxide, vinyl ether, maleic acid derivative, fumaric acid derivative, alkene, diene, alkyne, substituted diene, thiol, alcohol, amine, carboxylic acid, carboxylic anhydride, carboxylic acid halide, aldehyde, ketone, isocyanate, succinimide, carboxylic acid hydrazide, glycidyl ether, silane, siloxane, chlorosilane, alkoxysilane, azide, 2′-pyridyldithiol, phenylglyoxal, iodo, maleimide, aryl halides, imidoester, dibromopropionate, and iodacetyl. In addition to crosslinking, the surfactant layer can be formed by the condensation of polymeric surfactants by changing the solubility of the polymer or the polarity, pH, or temperature of the solvent.

Referring now to FIG. 10, the aqueous phase polymer component is then cross-linked to strengthen and form a robust hydrogel 28. In embodiments using cross-linkable surfactants, a polymer/surfactant emulsion containing such surfactants and the hydrogel-forming precursors (optionally with free radical initiators (either photo- or thermally-activated), hydrogel catalysts, hardening agents, etc.) would be coated onto the substrate, and the hydrogel and surfactant crosslinking can occur about simultaneously or sequentially. In other embodiments, crosslinking can be achieved by applying a catalyst and/or co-catalyst onto the surface of the emulsion layer 22, for example, by spraying or applying drops of a catalyst/co-catalyst solution. For example, in the use of a PEG-based hydrogel material composed of a diacetylene-functionalized PEG derivative, a catalyst/co-catalyst solution of copper sulfate (CuSO₄) and sodium ascorbate can be applied at about room temperature or higher. Further hardening can be applied as needed to produce a structure 28 (FIG. 12A) that is a robust mask for later etching.

Excess material can then be removed, as shown in FIGS. 11-11A, to expose the surfactant monolayer (SAM) 24 along the trench sidewalls 16 (and ends 18, referring to the embodiment in FIG. 9B). Removal of the excess material can be conducted, for example, using a mechanical planarization apparatus, such as a grinder. Planarization can also be performed using a chemical mechanical planarization (CMP) apparatus with an alkaline slurry containing abrasive particles, for example an alkaline silica or ceria slurry with potassium hydroxide (KOH), sodium hydroxide (NaOH), tetramethyl ammonium hydroxide (TMAH; (CH₃)₄NOH), and the like. Removal of the material can also be performed using an etch back process, such as a wet etch process (e.g., using basic conditions to remove a PEG hydrogel), or a dry etch (e.g., plasma etch) process to etch the hydrogel (and optionally included hardening agent), for example, a combination of oxygen for the carbonaceous components and a fluorocarbon for silica hardening agents (e.g., CH₂F₂, CHF₃, CF₄, etc.). Optionally, the hydrogel can be dried prior to a planarization or etch process to reduce the thickness and facilitate the removal process, provided that the structure of the hydrogel 28 has enough structural integrity to not shift during the drying process.

Referring now to FIGS. 12-12A, the surfactant layer 24 is then selectively removed leaving a void or channel 30 along the trench sidewalls 16 that is the width of layer 24 (e.g., up to about 10 nm wide) and the crosslinked hydrogel 28 intact within the center of the trenches 14. In embodiments in which the surfactant layer 24 is not crosslinked, selective removal of the surfactant layer can be achieved, for example, by a wet etch process with an appropriate solvent (e.g., water, alcohols, aromatic hydrocarbons such as toluene and xylene) or by dry etch. In other embodiments, a crosslinked surfactant layer 24 can be removed by a selective dry etch (e.g., plasma etch) process, for example, an oxygen plasma “ashing” process, or other appropriate technique.

The resulting structure is composed of a pair of channels (lines) 30 up to about 10 nm wide (e.g., about 3-10 nm wide) and registered to the trench sidewalls 16. Each pair of channels 30 within a trench 14 is separated from each other by the width (w_(h)) of the hydrogel within the trench, and from a channel in an adjacent trench by the width (w_(s)) of the spacer 12 a between the trenches 14. The hydrogel film can be then used, for example, as a lithographic template or mask to pattern (arrows ↓↓) the underlying substrate 10 in a semiconductor processing, for example, by a non-selective RIE etching process, to define a series of channel or grooves 32 (shown in phantom in FIG. 12A) in the sub-10 nanometer size range. The grooves 32 can then be filled, for example, with a conductive material (e.g., metal) to form nanowire channel arrays for transistor channels, semiconductor capacitors, and to form nanowire channel arrays for transistor gates and digit lines. The grooves may be filled with a dielectric material to define source/drain active areas. Further processing can then be performed as desired.

Another method according to an embodiment of the invention, illustrated with reference to FIGS. 13-19, utilizes a graphoepitaxy technique that involves the use of lithographical-defined (first) trench to direct a lamellar-phase block copolymer film to self assemble into a lamellar array of alternating perpendicular-oriented polymer-rich blocks that extend the length and are ordered and registered to the sidewalls of the (first) trench. Selective removal of one of the blocks forms a series of about 10-30 nanometer-scale parallel lines that can be used as a template or mask to etch about 10-30 nm grooves (second trenches) into the underlying substrate within the wider first trench. The above-described polymer/surfactant emulsion can then be formed within the second trenches and processed to form the hydrogel mask to etch a series of sub-10 nanometer-scale grooves in the underlying material layer.

To produce a polymer film within the first trench using a lamellar-phase block copolymer, the surfaces of the sidewalls and ends of the trench are preferential wetting by the one block of the copolymer and the trench floor is neutral wetting (equal affinity for both blocks of the copolymer) to allow both blocks of the copolymer material to wet the floor of the trench. Entropic forces drive the wetting of a neutral wetting surface by both blocks, resulting in the formation of a single layer of lamellae across the width of the trench.

In some embodiments, the second trenches are structured with hydrophilic floors and ends such that the aqueous phase of the emulsion wets both of those surfaces, and hydrophobic sidewalls such that the surfactant layer forms solely along that surface (as in FIG. 9).

For example, in an embodiment shown in FIGS. 13-13B, a substrate 10″ is provided bearing a neutral wetting surface 36″. The substrate 10″ can comprise, for example, silicon or amorphous (transparent) carbon or a metal film (e.g., gold, aluminum, etc.). The substrate 10″ overlies a sub-material layer 34″, which is in some embodiments comprises an oxide (e.g., silicon oxide, SiO_(x)), which is inherently hydrophilic.

As shown, silicon layer 10″ has been etched lithographically to form trenches 11″ to the underlying sub-SiO_(x) layer 34″, and the trenches filled with a SiO_(x) layer 13″ as described with reference to FIGS. 2-4B.

A neutral wetting layer 36″ is formed on the substrate 10″ prior to forming the overlying material layer 12″. As illustrated in FIGS. 14-14B, etching through the material layer 12″ to form the first trench 38″ exposes the underlying neutral wetting layer 36″ as the floor or bottom surface 40″ of the trench 38″.

A neutral wetting surface can be provided, for example, by applying a neutral wetting polymer to form a layer 36″ on the surface of the substrate 10″. In the use of a self-assembling (SA) diblock copolymer composed of PS-b-PMMA, a random PS:PMMA copolymer brush layer (PS-r-PMMA)) which exhibits non-preferential or neutral wetting toward PS and PMMA can be applied by spin-coating onto the surface of substrate 10″. The brush can be affixed by grafting (on an oxide substrate or native oxide layer) or by cross-linking (any surface) using UV radiation or thermal processing. For example, a random copolymer solution composed of PS and PMMA with hydroxyl end groups (e.g., about 58% PS) can be applied to the surface of the substrate 10″ as a layer about 5-10 nm thick and end-grafted by heating at about 160° C. for about 48 hours.

A trench floor that is neutral wetting to PS-b-PMMA can also be prepared by spin coating a photo- or thermally cross-linkable random copolymer such as benzocyclobutene- or azidomethylstyrene-functionalized random copolymers of styrene and methyl methacrylate (e.g., poly(styrene-r-benzocyclobutene-r-methyl methacrylate (PS-r-PMMA-r-BCB) onto the surface of the substrate 10″ and thermally crosslinking the polymer (e.g., about 200° C., 4 hours) to form a cross-linked polymer mat as a neutral wetting layer 36″.

Another neutral wetting surface for PS-b-PMMA can be provided by hydrogen-terminated silicon, which can be prepared by a conventional process, for example, by a fluoride ion etch of a silicon substrate 10″ (with native oxide present, about 12-15 Å) for example by immersion in aqueous solution of hydrogen fluoride (HF) and buffered HF or ammonium fluoride (NH₄F), by HF vapor treatment, by exposure to hot H₂ vapor or by a hydrogen plasma treatment (e.g., atomic hydrogen).

In another embodiment shown in FIG. 14C, the material layer 12″ can be formed on the substrate 10″ and etched to form the first trench 38″, and a neutral wetting material 36″ then applied to the trench floor 40″. For example, a cross-linkable random copolymer can be spin coated onto the surface of the substrate 10″ within the trench and crosslinked to form a crosslinked polymer mat as a neutral wetting layer 36″. Capillary forces pull the random copolymer to the bottom of the trench. Non-crosslinked polymer material can be subsequently removed. A neutral-wetting polymer (NWP) such as random copolymer of P(S-r-MMA-r-HEMA) can also be grafted selectively to a material layer, e.g., an oxide floor. See, for example, In et al., Langmuir, 2006, 22, 7855-7860, the disclosure of which is incorporated by reference herein. In other embodiments, an olefinic monomer such as PMMA or PS can be grafted onto an H-terminated silicon substrate 10″ (i.e., floor 40″) by an in situ free radical polymerization using a di-olefinic linker such divinyl benzene to produce an about 10-15 nm thick film.

As shown in FIGS. 14-14B, a material layer 12″ is formed on the substrate 10″ and patterned to form the first trench 38″ structured with a floor or bottom surface 40″, opposing sidewalls 42″, opposing ends (edges) 44″, a width (w), a length (l) and a depth (D). The first trench 38″ can be formed by a lithographic technique, for example, photolithography, extreme ultraviolet (EUV) lithography, proximity X-rays and electron beam (e-beam) lithography, as known and used in the art.

The trench sidewalls 42″ and ends 44″ are preferential wetting by one block of the copolymer to induce formation of lamellar polymer domains as the blocks self-assemble. The material layer 12″ defining the trench surfaces can be an inherently preferential wetting material, or in other embodiments, a layer of a preferential wetting material can be applied onto the surfaces of the trench. For example, in the use of poly(styrene-block-methyl methacrylate) (PS-b-PMMA), the material layer 12″ can be composed of an oxide (e.g., silicon oxide, SiO_(x)) or a clean silicon surface (with native silicon oxide), which exhibits preferential wetting toward the PMMA block to result in the assembly of a thin (e.g., ¼ pitch) interface layer of PMMA and alternating PMMA and PS lamellae (e.g., ½ pitch) within the trench in the use of a lamellar-phase block copolymer material. Other preferential wetting surfaces to PMMA can be provided, for example, by silicon nitride, silicon oxycarbide, polymethylmethacrylate (PMMA) polymer grafted to a sidewall material such as silicon oxide, and resist materials such as methacrylate-based resists. For example, a PMMA that is modified with a moiety containing one or more hydroxyl (—OH) groups (e.g., hydroxyethylmethacrylate) can be applied by spin coating and then heated (e.g., to about 170° C.) to allow the OH groups to end-graft to the oxide sidewalls 42″ and ends 44″ of the trench. Non-grafted material can be removed from the neutral wetting layer 36″ by rinsing with an appropriate solvent (e.g., toluene). See, for example, Mansky et al., Science, 1997, 275, 1458-1460, and In et al., Langmuir, 2006, 22, 7855-7860, the disclosures of which are incorporated by reference herein.

The trench sidewalls, ends and floor influence the structuring of the array of lamellae within the trench. The boundary conditions of the trench sidewalls in both the x- and y-axis impose a structure such that the trench contains n number of lamellae. Factors in forming a single array or layer of lamellae within the trench include the width and depth of the trench, the formulation of the block copolymer to achieve the desired pitch (L_(o)), and the thickness (t) of the copolymer film.

The trench 38″ is constructed with a width (w) such that a lamellar-forming block copolymer (or blend) will self assemble upon annealing into a single layer of “n” lamellae spanning the width (w) of the trench, with each lamellar domain being separated by a value of L_(o) (from center-to-center). The width (w) of the first trench 38″ is a multiple of the inherent pitch value (L_(o)) of the block copolymer being equal to or about nL_(o) (“n*L_(o)”), typically ranging from about n*10 to about n*100 nm (with n being the number of features or structures). In embodiments of the inventions, the depth (D) of the trench 38″ is greater than or at about L_(o), as illustrated in FIG. 14A. The application and annealing of a block copolymer material having an inherent pitch value of L_(o) in a trench 38″ having a width (w) at or about L_(o) will result in the formation of a single layer of “n” lamellae spanning the width and registered to the sidewalls 42″ for the length of the trench. In some embodiments, the trench dimension is about 55-80 nm wide (w) and about 1600-2400 μm in length (l), with a depth (D) of about 50-500 nm.

Referring now to FIG. 15, a layer 46″ of a lamellar-phase self-assembling (SA) block copolymer material having an inherent pitch at or about L_(o) (or a ternary blend of block copolymer and homopolymers blended to have a pitch at or about L_(o)) is then deposited, typically by spin casting (spin-coating), onto the floor 40″ of the trench. The block copolymer material can be deposited onto the patterned surface by spin casting from a dilute solution (e.g., about 0.25-2 wt % solution) of the copolymer in an organic solvent such as dichloroethane (CH₂Cl₂) or toluene, for example.

The lamellar-phase block copolymer material is deposited into the trench 38″ to a thickness (t) less than the trench depth (D), for example, at about one-half of the trench depth, and at or about the L_(o) value of the block copolymer material such that the copolymer film layer will self assemble upon annealing to form a single layer of lamellae across the width (w_(t)) of the trench. A typical thickness (t) of the block copolymer film 46″ is about ±20% of the L_(o) value of the polymer (e.g., about 10-100 nm) to form alternating polymer-rich lamellar blocks, each with a width of about L_(o) (e.g., 25-35 nm) across the width (w) of the trench 38″. The thickness (t) of the film 46″ can be measured, for example, by ellipsometry techniques. As shown, a thin film of less than L_(o) of the block copolymer material can be deposited onto the surface of the material layer 12″; this thin film will not self-assemble as it is not thick enough to form structures.

The volume fractions of the two blocks (AB) of the lamellar-forming diblock copolymer are generally at a ratio between about 50:50 and 60:40. An example of a lamellae-forming symmetric diblock copolymer is poly(styrene-block-methyl methacrylate) (PS-b-PMMA), with a weight ratio of about 50:50 (PS:PMMA) and total molecular weight (M_(n)) of about 51 kg/mol.

Although diblock copolymers are used in the illustrative embodiment, other types of block copolymers (i.e., triblock or triblock or multiblock copolymers) can be used. Examples of diblock copolymers include poly(styrene-block-methyl methacrylate) (PS-b-PMMA), polyethyleneoxide-polyisoprene, polyethyleneoxide-polybutadiene, polyethyleleoxide-polystyrene, polyetheleneoxide-polymethylmethacrylate, polystyrene-polyvinylpyridine, polystyrene-polyisoprene (PS-b-PI), polystyrene-polybutadiene, polybutadiene-polyvinylpyridine, and polyisoprene-polymethylmethacrylate, among others. Examples of triblock copolymers include poly(styrene-block methyl methacrylate-block-ethylene oxide). One of the polymer blocks of the block copolymer should be selectively and readily removable in order to fabricate an etch mask or template from the annealed film.

The block copolymer material can also be formulated as a binary or ternary blend comprising a SA block copolymer and one or more homopolymers of the same type of polymers as the polymer blocks in the block copolymer, to produce blends that swell the size of the polymer domains and increase the L_(o) value of the polymer. The volume fraction of the homopolymers can range from 0 to about 40%. An example of a ternary diblock copolymer blend is a PS-b-PMMA/PS/PMMA blend, for example, 46K/21K PS-b-PMMA containing 40% 20K polystyrene and 20K poly(methylmethacrylate). The L_(o) value of the polymer can also be modified by adjusting the molecular weight of the block copolymer, e.g., for lamellae, L_(o)˜(MW)^(2/3).

Referring now to FIGS. 16-16B, the block copolymer film 46″ is then annealed to form a self-assembled lamellar film 48″, for example, by thermal annealing to above the glass transition temperature of the component blocks of the copolymer material to cause the polymer blocks to separate and self assemble into blocks 50″, 52″ according to the preferential and neutral wetting of the trench surfaces 40″, 42″, 44″. A PS-b-PMMA copolymer film can be annealed, for example, at about 180-195° C. in a vacuum oven for about 1-170 hours to produce a self-assembled film. The film can also be solvent annealed, for example, by slowly swelling both blocks of the film with a solvent, then slowly evaporating the solvent.

The constraints provided by the width (w) of the first trench 38″ and the character of the block copolymer composition combined with preferential and neutral wetting surfaces within the trench results, upon annealing, in a single layer of n perpendicular-oriented, alternating lamellar polymer-rich blocks extending the length (l) and spanning the width (w) of the trench 38″ at an average pitch value of at or about L_(o) (center-to-center). The number “n” or pitches of lamellar blocks within the trench is according to the width (w) of the trench and the molecular weight (MW) of the copolymer. For example, depositing and annealing an about 50:50 PS:PMMA block copolymer film (M_(n)=51 kg/mol; L_(o)=32 nm) in an about 250 nm wide trench will subdivide the trench into about eight (8) lamellar structures. The perpendicular orientation of lamellae can be examined, for example, using atomic force microscopy (AFM), transmission electron microscopy (TEM), or scanning electron microscopy (SEM).

The annealed and ordered film 48″ can then be treated to crosslink the polymer segments to fix and enhance the strength of the self-assembled polymer blocks 50″, 52″ within the trench 38″ (e.g., to crosslink the PS segments). The polymers can be structured to inherently crosslink (e.g., upon UV exposure through a reticle), or one or both of the polymer blocks of the copolymer material can be formulated to contain a crosslinking agent. The substrate can then be washed with an appropriate solvent such as toluene, to remove the non-crosslinked portions of the film 48″ on surfaces outside the trench (e.g., on the crest 12 a″) leaving the registered, self-assembled film 48″ within the first trench 38″ (FIG. 16A).

Referring now to FIGS. 17-17 B, after the lamellar-phase block copolymer material is annealed and ordered to form film 48″, one of the block components (e.g., block 50″) can be selectively removed to produce a thin film 54″ having registered and parallel oriented slits (openings) 56″ that can be used, for example, as a lithographic template or mask to pattern the underlying substrate 10″ within the first trench 38″ in a semiconductor processing to define regular patterns in the nanometer size range (i.e., about 10-100 nm). For example, selective removal of the PMMA domains 50″ will result in openings (slits) 56″ separated by vertically oriented PS lamellar domains 52″ with the trench floor 40″ (e.g., neutral wetting layer 36″ over substrate 10″) exposed where the PMMA blocks were removed. Removal of the PMMA phase domains 50″ can be performed, for example, by application of an oxygen (O₂) plasma or CF₄ plasma (e.g., about 3:1 selective for PMMA), or by a chemical dissolution process such as acetic acid sonication by first irradiating the sample (ultraviolet (UV) radiation, 1 J/cm̂2 254 nm light), then ultrasonicating the film in glacial acetic acid, ultrasonicating in deionized water, and rinsing the film in deionized water to remove the degraded PMMA.

In some embodiments, the resulting film 54″ will have a corrugated surface that defines a linear pattern of fine, nanometer-scale parallel slits (openings) 56″ about 10-60 nm wide and extending the length of the first trench 38″, the individual slits separated by a polymer matrix 52″ (e.g., of PS) about 10-60 nm wide. For example, removal of the PMMA domains (from PS-b-PMMA of MW 51K) affords a PS mask of sublithographic dimensions, for example, a pitch of about 32 nm (16 nm PS domain). A smaller pitch can be dialed in by using lower molecular weight diblock copolymers.

The film 54″ can then be used as a lithographic template or etch mask to pattern (arrows ↓↓) the underlying substrate 10″ (e.g., silicon), for example, by a non-selective RIE etching process, to delineate a series of trenches (grooves, channels) 14″ as illustrated in FIGS. 18A-18B. The residual film 54″ (e.g., polystyrene) can then be removed, for example, by an etch using a low density plasma of oxygen, resulting in the structure shown in FIG. 19.

Etching through the substrate 10″ (e.g., silicon) to form the trenches 14″ exposes the underlying sub-material layer 34″, which is oxide in the illustrated example, as the floor or bottom surface 20″ of the trenches 14″, the oxide layer 13″ as the ends 18″, and substrate 10″, which is silicon in the illustrated example, as the sidewalls 16″. In some embodiments, the dimension of the trenches 14″ is about 10-60 nm wide (w_(t)) and with a depth (D_(t)) of about 10-100 nm.

As previously described with reference to FIGS. 5-5B, an aqueous fluoride treatment can be briefly conducted to remove native oxide on the silicon layer 10″ (to form H-terminated silicon sidewalls) while minimizing etching of the SiO_(x) layers 13″, 34″. A PEG coupling agent can then be applied as previously described, for example, by grafting a ligand with a reactive end group such as a mono-hydroxylated PEG ligand to hydroxyl (—OH) groups on the SiO_(x) floor 20″ and ends 18″ of the trenches 14″ in an inert atmosphere (e.g., nitrogen, argon, etc.) to minimize the reformation of native oxide on the silicon sidewalls 16″.

As described with reference to FIGS. 9-12A, the previously described aqueous polymer/surfactant emulsion can then be applied to fill the trenches 14″ and processed to form an etch mask composed of the hydrogel material to etch the sub-material layer 34′ to form grooves or channels (e.g., 32 in FIGS. 12-12A).

Another method according to an embodiment of the invention is illustrated with reference to FIGS. 20-24. In some embodiments, a substrate as described with respect to FIGS. 5-5B (or FIGS. 8-8A) can be prepared having trenches 14′″ with a hydrophilic floor 20′″ and ends 18′″ (e.g., of SiO_(x)) and hydrophobic sidewalls 16′″ (e.g., H-terminated silicon).

Referring now to FIG. 20, an aqueous emulsion 58′″ composed of a self-assembling amphiphilic agent, e.g., surfactant monomers, for example, as described above with reference to U.S. Pat. No. 6,884,842 (Sloane), containing olefinic group(s) with surface functional head groups that are complementary to a substrate surface, can be applied to fill the trench 14′″ and over the material layer 12′″. The emulsion can be applied, for example, by casting, dip coating, spray coating, knife-edge coating, spin casting (spin-coating), and the like, such that the emulsion layer 58′″ is maintained in a liquid consistency to allow a layer of the amphiphilic agent (e.g., surfactant) to form at the trench sidewalls. Application of the emulsion can be conducted at about room temperature (e.g., about 20-25° C.) to up to about 95° C. The amphiphilic agent (e.g., surfactant monomers) will self-assemble to form a monolayer 24′″ on the hydrophobic sidewalls 16′″ (e.g., H-terminated silicon) of the trenches 14′″. The monomers can then be polymerized and crosslinked, for example, by free-radical polymerization, to form a robust, thin, insoluble surfactant monolayer 24′″.

As shown in FIG. 21, the monolayer can then be dried, for example, by heating and/or blow-drying with a dry gas such as nitrogen, argon, and clean dry air, or by a Marangoni drying technique in which the structure is immersed in a DI water bath and drawn through a layer of a water-miscible solvent that is more volatile than water such as isopropyl alcohol (IPA), which rests on the surface of the DI water bath. Micellar structures or other material that has precipitated onto the trench floor and sidewalls during crosslinking of the surfactant monomers can be removed, for example, by rinsing or sonicating using a liquid that does not swell the crosslinked surfactant material or cause dewetting of the surfactant monolayer, for example, water, methanol and isopropanol.

Referring now to FIG. 22, an inorganic material layer 60′″ such as a dielectric material can then be deposited, for example, by a chemical deposition process at a low temperature such that the surfactant monolayer is not degraded (e.g., below about 150° C.), to fill the trenches 14′″. Suitable dielectric materials include, for example, silicon oxide (SiO_(x)), aluminum oxide (Al₂O₃), tantalum oxide (TaO_(x)), silicon carbide (SiC), hafnium oxide (HfO₂), hafnium aluminum oxide (HfAlO), silicon carbon nitride (SiCN), silicon nitride (SiN₄), yttrium oxide (YO₂), and tantalum pentoxide (Ta₂O₅). Excess material can then be removed as in FIG. 23, for example, by mechanical planarization, chemical mechanical planarization, or an etch back process, to expose the surfactant monolayer 24′″ along the trench sidewalls 16′″.

As depicted in FIG. 24, the surfactant layer 24′″ along the trench sidewalls 16′″ can then be selectively removed leaving a channel or gap 30′″ that is the width of the surfactant monolayer 24′″ (e.g., up to about 10 nm wide), with the inorganic material layer 60′″ remaining intact within the center of the trenches 14′″. Selective removal of the crosslinked surfactant layer 24′″ can be achieved, for example, by a selective dry etch (e.g., plasma etch) process, for example, an oxygen plasma “ashing” process, or other appropriate technique.

The resulting structure is composed of a pair of channels (lines) 30′″ up to about 10 nm wide (e.g., about 3-10 nm wide) and registered to the trench sidewalls 16′″. Each pair of channels 30′″ within a trench 14′″ is separated from each other by the width (w_(x)) of the inorganic material layer 60′″ within the trench, and from a channel in an adjacent trench by the width (w_(s)) of the spacer 12 a′″ between the trenches 14′″. The inorganic material layer 60′″ can be then used, for example, as a lithographic template or mask to pattern (arrows ↓↓) the underlying substrate 10′″, for example, by a non-selective RIE etching process, to define a series of channels or grooves 32′″ (shown in phantom in FIG. 24) in the sub-10 nanometer size range, which can be filled with metal or other conductive material, or dielectric material, for example.

The described films are useful as lithographic templates or etch masks for producing close pitched, ordered and registered, nanoscale channel and grooves that are sub-10 nm wide and several nanometers in length, for producing features such as floating gates for NAND flash with nanoscale dimensions. By comparison, photolithography techniques are unable to produce channels much below 60 nm wide without high expense. Resolution can exceed other techniques for forming channels and grooves, including self-assembling block copolymer processing and conventional photolithography. Fabrication costs utilizing methods of the disclosure are far less than electron beam (E-beam) or EUV photolithographies which have comparable resolution.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations that operate according to the principles of the invention as described. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. The disclosures of patents, references and publications cited in the application are incorporated by reference herein. 

1. A method for fabricating an etch mask on a substrate, comprising: forming a layer of an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer in a trench having sidewalls and a floor, wherein the amphiphilic agent forms a layer selectively on the sidewalls of the trench and the polymer selectively wets the floor of the trench; causing the polymer to form a hydrogel; and removing the layer of the amphiphilic agent to form an opening between the hydrogel and the sidewalls of the trench and expose the floor of the trench.
 2. The method of claim 1, wherein the opening between the hydrogel and the trench sidewalls is up to about 10 nm.
 3. The method of claim 1, wherein the opening between the hydrogel and the trench sidewalls is about 3-10 nm.
 4. The method of claim 1, further comprising removing a portion of the hydrogel to expose the layer of the amphiphilic agent within the trench.
 5. The method of claim 4, further comprising drying the hydrogel prior to removing the hydrogel.
 6. A method for fabricating an etch mask on a substrate, comprising: depositing an aqueous emulsion comprising an amphiphilic surfactant and a water-soluble, hydrogel-forming polymer into a trench having hydrophobic sidewalls and a hydrophilic floor defined by a substrate, such that the surfactant forms a layer selectively on the sidewalls and the polymer orients selectively to the floor of the trench; forming the polymer into a hydrogel; and removing the surfactant layer to form a gap between the hydrogel and the trench sidewalls and expose the substrate at the floor of the trench.
 7. The method of claim 6, wherein the polymer is selected from the group consisting of poly(ethylene oxide) and poly(ethylene glycol).
 8. The method of claim 6, wherein the polymer is selected from the group consisting of poly(vinyl alcohol) and poly(saccharide).
 9. A method for fabricating an etch mask on a substrate, comprising: selectively forming a hydrophobic layer on sidewalls of a trench and a hydrophilic layer on a floor of the trench; forming a layer of an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer in the trench, wherein the amphiphilic agent forms a layer selectively on the sidewalls of the trench and the polymer orients selectively to the floor of the trench; causing the polymer to form a hydrogel; and selectively removing the layer of the amphiphilic agent to form an opening between the hydrogel and the sidewalls of the trench and expose the floor of the trench.
 10. The method of claim 9, wherein the trench sidewalls comprise hydrogen-terminated silicon.
 11. The method of claim 9, wherein the trench floor comprise a hydrophilic polymer.
 12. The method of claim 9, wherein forming the hydrophilic layer comprises grafting a hydrophilic polymer to the floor of the trench with reactive groups of the hydrophilic polymer oriented toward the center of the trench.
 13. The method of claim 9, wherein ends of the trench are hydrophilic.
 14. The method of claim 9, wherein the emulsion further comprises an organic solvent.
 15. The method of claim 9, wherein the emulsion further comprises a hardening agent.
 16. The method of claim 9, further comprising applying a silicon ester to the hydrogel to effect a sol-gel reaction.
 17. A method for fabricating an etch mask on a substrate, comprising: selectively forming a hydrophobic layer on sidewalls of a trench and a hydrophilic layer on a floor of the trench; forming a layer of an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer in the trench, wherein the amphiphilic agent forms a layer selectively on the sidewalls of the trench and the polymer orients selectively to the floor of the trench; crosslinking the polymer to form a hydrogel; and removing the layer of the amphiphilic agent to form an opening between the hydrogel and the sidewalls of the trench and expose the floor of the trench.
 18. The method of claim 17, wherein crosslinking the polymer comprises applying a catalyst onto the emulsion within the trench.
 19. The method of claim 17, further comprising crosslinking the layer of the amphiphilic agent.
 20. A method for fabricating an etch mask on a substrate, comprising: forming a layer of a self-assembled lamellar-phase block copolymer within a first trench having sidewalls and a floor defined by a substrate; selectively removing one of the blocks of the self-assembled layer to form openings in the layer exposing the substrate at the floor of the trench; etching through the openings to form second trenches in the substrate, the second trenches having hydrophobic sidewalls and a hydrophilic floor; depositing an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer into the second trenches such that the amphiphilic agent forms a layer selectively on the sidewalls and the polymer orients selectively to the floor of the second trenches; forming the polymer into a hydrogel; and removing the amphiphilic agent layer to form a gap between the hydrogel and the trench sidewalls and expose the substrate at the floor of the second trenches.
 21. A method for fabricating an etch mask on a substrate, comprising: forming a layer of a self-assembled, lamellar-phase block copolymer within a first trench defined by a substrate and having sidewalls that are preferential wetting to one block of the block copolymer, a floor that is neutral wetting to both blocks of the block copolymer, a width and a length, the self-assembled polymer layer comprising alternating lamellar blocks spanning the width of the trench and oriented perpendicular to the trench floor and substantially parallel to the sidewalls; selectively removing one of the blocks of the self-assembled layer to form openings in the polymer layer exposing the substrate at the floor of the trench; etching through the openings to form second trenches in the substrate, the second trenches having hydrophobic sidewalls and a hydrophilic floor; depositing an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer into the second trenches such that the amphiphilic agent forms a layer selectively on the sidewalls and the polymer orients selectively to the floor of the second trenches; forming the polymer into a hydrogel; and removing the amphiphilic agent layer to form a gap between the hydrogel and the trench sidewalls and expose the substrate at the floor of the second trenches.
 22. A method for fabricating an etch mask on a substrate, comprising: forming a film comprising a self-assembled lamellar-phase block copolymer within a first trench in a substrate to a thickness of about L_(o), the block copolymer comprising first and second polymer blocks, and the trench having sidewalls that are preferential wetting to one block of the block copolymer, a floor that is neutral wetting to both blocks of the block copolymer, a width of about nL_(o) and a length; the self-assembled polymer film comprising a single array of perpendicular-oriented lamellar polymer domains spanning the width and extending the length of the trench in a substantially parallel orientation to the sidewalls; selectively removing one of the blocks of the self-assembled layer to form openings in the polymer layer exposing the substrate at the floor of the trench; etching through the openings to form second trenches in the substrate, the second trenches having hydrophobic sidewalls and a hydrophilic floor; depositing an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer into the second trenches such that the amphiphilic agent forms a layer selectively on the sidewalls and the polymer orients selectively to the floor of the second trenches; forming the polymer into a hydrogel; and removing the amphiphilic agent layer to form a gap between the hydrogel and the trench sidewalls and expose the substrate at the floor of the second trenches.
 23. A method for fabricating an etch mask on a substrate, comprising: forming a material layer over a substrate having a surface being neutral wetting to both blocks of a lamellar-phase block copolymer; forming a first trench in the material layer having a floor, sidewalls, ends, a width and a length, to expose the neutral wetting surface of the substrate at the floor of the first trench, the sidewalls being preferential wetting to one of the blocks of the lamellar-phase block copolymer; forming a layer of the lamellar-phase block copolymer within the first trench; causing the copolymer layer to self-assemble into a film comprising alternating lamellar blocks spanning the width of the trench and oriented perpendicular to the trench floor and substantially parallel to the sidewalls; selectively removing one of the lamellar blocks of the self-assembled film to form openings exposing the substrate at the floor of the trench; etching through the openings to form second trenches in the substrate, the second trenches having hydrophobic sidewalls and a hydrophilic floor; depositing an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer into the second trenches wherein the amphiphilic agent forms a layer selectively on the sidewalls and the polymer selectively wets the floor of the second trenches; causing the polymer to form a hydrogel; and removing the layer of the amphiphilic agent to form a gap between the hydrogel and the trench sidewalls and expose the substrate at the floor of the second trenches.
 24. The method of claim 23, wherein the neutral wetting surface on the substrate comprises hydrogen-terminated silicon.
 25. The method of claim 23, wherein the neutral wetting surface on the substrate comprises a random copolymer.
 26. The method of claim 23, wherein the sidewalls of the first trench comprise oxide.
 27. The method of claim 23, wherein the sidewalls of the first trench comprise silicon nitride or silicon oxycarbide.
 28. The method of claim 23, wherein the sidewalls of the first trench comprise a methacrylate-based moiety.
 29. A method for fabricating channels in a substrate, comprising: forming a layer of an aqueous emulsion comprising an amphiphilic agent and a water-soluble, hydrogel-forming polymer in a trench having sidewalls and a floor, wherein the amphiphilic agent forms a layer selectively on the sidewalls of the trench and the polymer selectively wets the floor of the trench; causing the polymer to form a hydrogel; removing the layer of the amphiphilic agent to form an opening between the hydrogel and the sidewalls of the trench and expose the floor of the trench; and etching an underlying substrate through the openings to form the channels in the substrate.
 30. A method for fabricating an etch mask on a substrate, comprising: forming a layer of an aqueous emulsion comprising an amphiphilic material in a trench having hydrophobic sidewalls and a floor, wherein the amphiphilic material forms a layer selectively on the sidewalls of the trench; crosslinking the amphiphilic material layer; drying the amphiphilic material layer; filling the trench with an inorganic material; and removing the amphiphilic material layer to form an opening between the inorganic material and the sidewalls of the trench and expose the floor of the trench.
 31. The method of claim 30, wherein the inorganic material comprises a dielectric material.
 32. The method of claim 30, further comprising, after filling the trench, removing a portion of the inorganic material and amphiphilic material above the trench to expose the amphiphilic material layer on the sidewalls of the trench. 33-38. (canceled) 